Method &amp; Apparatus for Producing Biochar

ABSTRACT

The present disclosure provides, at least in part, a system for pyrolysis of biomass, the system comprising: (a) a reactor having a retort extending therethrough, said retort comprising a conveyor, an inlet, and an outlet; the reactor further comprising at least one thermosensor, the thermosensor capable of generating a signal when the temperature is above optimal levels; (b) a heating system adapted to heat the reactor; (c) a syn-gas management system; the management system comprising a syn-gas storage tank having an inlet and an outlet, said inlet in fluid communication with the reactor, and said outlet in fluid communication with the heating system and syn-gas outlet such as a flare or storage tank wherein the communication is controlled via a valve configurable between at least a first position where flow is directed to the heating system and a second position where flow is directed to the flare pipe; and (d) a controller in communication with the thermosensor and the valve; wherein the controller switches the valve from the first position to the second position upon receiving a signal from the thermosensor that the temperature in the reactor is above optimal levels.

FIELD

The present disclosure provides a system and method for producingbiochar from biomass. In particular, the present disclosure providespyrolytic systems and methods of producing biochar.

BACKGROUND

There is an increasing interest in fuel derived from biomass such asforestry, agricultural products or waste. There are various technologiesfor converting biomass to fuel such as direct burning, co-firing,gasification, fermentation, pyrolysis, and the like. Depending on thefeedstock and the process used the resultant product will have differentutilities and properties. In many cases, it is desired to produce aproduct to replace a fossil fuel leading to sustainability andenvironmental benefits.

Pyrolysis is a type of thermal decomposition in which a substance isheated in the absence of oxygen, or under limited oxygen conditions.Pyrolysis may be termed ‘fast’ or ‘slow’ depending on the heating rateand residence time of the biomass. In the case of dried biomass, thepyrolysis can result in decomposition into three major products:bio-char (also known as biochar or biocoal), bio-oil, and syn-gas. Thedevelopment of efficacious technology that enables the pyrolyticconversion of lower-value biomass into higher energy bio-fuels andproducts (bio-char/bio-coal and bio-oil) is desirable. In particular, itis of interest to provide technology for the production, optimization,and delivery of bio-fuels, particularly biochar, to be used in variousagricultural, forestry, and industrial applications that can benefitfrom using renewable fuel sources

Pyrolysis for the conversion of biomass into fuel products aredescribed, for example, in CA 2,242,279 which discloses an apparatus forcontinuous charcoal production; which CA 2,539,012 discloses a closedretort charcoal reactor system; CA 2,629,417 which discloses systems andmethods for the continuous production of charcoal by pyrolysis oforganic feed.

Although pyrolysis systems are known, to date they have met with limitedcommercial success. Several factors can affect the utility of suchsystems including the availability, moisture content and cost totransport the feedstock. As well as the efficiency, robustness andflexibility of the system.

It would be advantageous to have a relatively inexpensive, transportableand/or modular pyrolysis system for producing biochar. The system may besimple, robust and/or flexible enough to handle a variety of locations,feedstocks and conditions.

SUMMARY

The disclosure provides, at least in part, a system for producingbiochar from biomass. The present systems may be modular comprising, forexample, a reactor module and a syn-gas management module.

As used herein, the term ‘biomass’ refers to material derived fromnon-fossilized organic material, including plant matter such aslignocellulosic material and animal material such as wastes, suitablefor conversion into biofuels.

As used herein, the term ‘pyrolysis’ refers to thermal decomposition inwhich a substance is heated in the absence of substantial amounts ofoxygen.

As used herein, the term ‘biochar’ or ‘biocoal’ refers to pyrolyzedbiomass. Generally bio-char will have a calorific value of about 15MJ/Kg or greater, such as about 17 MJ/Kg or greater, or about 19 MJ/Kgor greater, about 21 MJ/Kg or greater, about 23 MJ/Kg or greater, about25 MJ/Kg or greater, about 27 MJ/Kg or greater, about 29 MJ/Kg orgreater.

As used herein, “a” or “an” means “one or more”.

This summary does not necessarily describe all features of theinvention. Other aspects, features and advantages of the invention willbe apparent to those of ordinary skill in the art upon review of thefollowing description of specific embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings, which illustrate one or more exemplarynon-limiting embodiments:

FIG. 1 shows a general flow diagram of an exemplary biomass pyrolysissystem according to the present disclosure;

FIG. 2 shows a schematic of a biomass pyrolysis system;

FIG. 3 shows the phases of biomass decomposition due to increasingtemperature (a) and a typical mass loss profile of biomass undergoingpyrolysis (b).

DETAILED DESCRIPTION

The present disclosure provides, at least in part, a system forpyrolysis of biomass, the system comprising:

-   -   (a) a reactor having a retort extending therethrough, said        retort comprising a suitable conveyor such as, for example, an        auger or paddle conveyor, an inlet, and an outlet; the reactor        further comprising at least one thermosensor, the thermosensor        capable of generating a signal when the temperature is above        optimal levels;    -   (b) a heating system adapted to heat the reactor;    -   (c) a syn-gas management system; the management system        comprising a syn-gas storage tank having an inlet and an outlet,        said inlet in fluid communication with the reactor, and said        outlet in fluid communication with the heating system and a        syn-gas outlet such as a flare or storage tank wherein the        communication is controlled via a valve configurable between at        least a first position where flow is directed to the heating        system and a second position where flow is directed to the        syn-gas outlet; and    -   (d) a controller in communication with the thermosensor and the        valve;        wherein the controller switches the valve from the first        position to the second position upon receiving a signal from the        thermosensor that the temperature in the reactor is above        optimal levels.

The present disclosure provides, at least in part, a system forpyrolysis of biomass, the system comprising:

-   -   (a) a reactor having a retort extending therethrough, said        retort comprising a suitable conveyor such as, for example, an        auger or paddle conveyor, an inlet, and an outlet; the reactor        further comprising at least one thermosensor, the thermosensor        capable of generating a signal when the temperature is below        optimal levels;    -   (b) a heating system adapted to heat the reactor;    -   (c) a syn-gas management system; the management system        comprising a syn-gas storage tank having an inlet and an outlet,        said inlet in fluid communication with the reactor, and said        outlet in fluid communication with the heating system and a        syn-gas outlet such as a flare or storage tank wherein the        communication is controlled via a valve configurable between at        least a first position where flow is directed to the heating        system and a second position where flow is directed to the        syn-gas outlet; and    -   (d) a controller in communication with the thermosensor and the        valve;        wherein the controller switches the valve from the second        position to the first position upon receiving a signal from the        thermosensor that the temperature in the reactor is below        optimal levels.

The present thermosensor may be capable of generating a signal when thetemperature is above and below optimal levels. The temperature value atabove or below which the thermosensor generates a signal may bepredetermined. Such value may be altered depending on a variety offactors such as the needs of a particular production run, the feedstock,the output desired, or the like.

The bio-char produced via the present process may have a calorific valueof about 18 MJ/Kg or greater, about 22 MJ/Kg or greater, about 24 MJ/Kgor greater, about 26 MJ/Kg or greater, about 28 MJ/Kg or greater, about30 MJ/Kg or greater. The present bio-char may have an energy density ofabout 4 MEL or greater, about 6 MEL or greater, about 8 MEL or greater,about 10 MEL or greater.

The present bio-char may be hydrophobic. For example, if processed attemperatures under about 400° C. the bio-char may be hydrophobic. Thepresent bio-char may be hydrophilic. For example, if processed attemperatures above about 400° C. the bio-char may be hydrophilic. Forexample, the present bio-char may have a water contact angle rangingfrom about 102° to about 20° depending on process temperature.

The present biochar preferably is grindable. The coal industry uses theHardgrove Grindability Index (“HGI”) as a standard test to measuregrindability where samples are compared to a standard reference sample(“SRS”). For example, if the grindability of a sample was equal to theSRS coal, it would score 50. A score of less than 50 would indicate asample is harder to grind and a score of greater than 50 would indicateis easier. The present biochar preferably has a HGI of about 50 orgreater, about 52 or greater, about 54 or greater, about 56 or greater,about 58 or greater, about 60 or greater.

The present disclosure provides a reactor for converting biomass intobiochar. The reactor has at least one retort extending through it. Forexample, the reactor may have two, three, four, or more retorts. It ispreferred that the reactor have at least four retorts. The retort maycomprise a suitable conveyor such as, for example, an auger or paddleconveyor, an inlet and an outlet. The inlet receives biomass whichpasses through the reactor on the auger to the outlet.

The reactor further comprises a heating system which heats the biomassas it passes through the reactor. The heating system can heat thebiomass to a temperature suitable to cause pyrolysis of biomass. Theheating system may be any suitable design such as, for example, aplurality of heating elements, heat exchangers, or burners throughoutthe length of the reactor.

The reactor comprises one or more thermosensors. The thermosensors maybe used to monitor the temperature of within the reactor enabling thetemperature to be kept at the appropriate level to achieve the desiredresult. Multiple sensors may allow for more accurate assessment of thetemperature at different points in the reactor. For example, based onthe temperature reading the heating may be increased or decreased.

Certain exemplary embodiments of the present disclosure comprise one ormore additional sensors such as, for example, a sensor for sensing thespeed of the auger. This sensor enables the controller to assess thespeed with which the biomass is moving through the retort. If this speedis too slow the controller may cause the speed to increase or if thespeed is too fast the controller may cause the speed to decrease.

In certain exemplary embodiments of the present disclosure, the reactorproduces a biochar stream and a gaseous stream. Biochar can have utilityas a fuel source, soil additive, or the like. The gaseous stream maycomprise condensable and non-condensable components. The condensablecomponents may, for example, be condensed to form pyrolysis oil(bio-oil). Bio-oil may be used as a petroleum substitute. Thenon-condensable gases (syn-gas) may be combustible and used, forexample, to fuel the reactor heating system. The biochar stream may exitthe reactor via a biochar delivery system such as described furtherherein. The gaseous stream may exit the reactor via a gas collectionsystem such as described further herein.

The present system may comprise a biochar delivery system for receivingthe biochar exiting the reactor. The delivery system receives thebiochar stream from the retort via the outlet. The system may include achar cooling means. Any suitable cooling means may be used such asdirect contact with a cooling medium, indirect contact with a coolingmedium, direct contact fluid quenching, or the like. For example, themeans may be an auger which moves the hot biochar through a cooling zoneto compaction and/or bagging area. An airlock such as a rotary valveairlock may be positioned between the cooling zone and thecompaction/bagging area. The cooling of the biochar may be aided by theapplication of a liquid such as water.

It is possible enrich the biochar with additives such as nutrients orminerals. The resultant biochar could derive advantageous propertiesfrom such enrichment. For example, when used as a soil additive theaddition of nutrients and minerals markedly improves the performance ofthe product. Examples of minerals include, but are not limited to,nitrogen, sulphur, magnesium, calcium, phosphorous, potassium, iron,manganese, copper, zinc, boron, chlorine, molybdenum, nickel, cobalt,aluminum, silicon, selenium, or sodium. Examples of nutrients includecompost tea, humic and fulvic acids, plant hormones, and other solutionsof benefit to plant growth and soil health such as buffers, pHconditioners, and the like.

The addition of the additives to the bio-char may be achieved in anysuitable manner. For example, additives may be applied at the biochardelivery system. Additives can be introduced to the cooling liquid andapplied to the biochar at the cooling zone. As the cooling liquid boilsoff the additives can be left behind on the char. Additives may beintroduced as a solid and, for example, incorporated through mixing inthe cooling zone.

Gases may exit the retort(s) via a gas collection system. The system maybe in any suitable form but can advantageously be a series of pipesdispersed throughout the reactor such that gas developed in theretort(s) during the pyrolysis process enters the pipes and is carriedout of the reactor. Where the reactor comprises more than one retort itis preferred that each retort have a separate gas collection pipe. Eachretort may have more than one gas collection pipe. The separate pipesmay feed into a gas collection module but it has been found that havingseparate pipes running from a section of the retort that has been shownto correspond with a particular biomass temperature and thermochemicalstage of decomposition (see FIG. 3) to a common gas manifold improvesefficiency of gas collection and reduces reactor downtime. The specificpositioning of these separate pipes along the retort can improveefficiency.

The reactor comprising one or more retorts, one or more thermosensors,and a heating system may be in the form of a module. This can aid in thetransportation of the pyrolysis system to various locations. The reactormodule may also comprise a gas collection system.

The present system comprises a syn-gas management system. The system isadapted to receive the gaseous stream from the reactor, for example viathe gas collection system. The gaseous stream may comprise condensablecomponents. The syn-gas management system may comprise a condenser toremove at least some of the condensable components to form bio-oil. Theresultant oil may be stored in one or more bio-oil storage tanks. Thesystem may comprise a pump such as, for example, a pump capable ofcreating at least a partial vacuum. The pump may be positioneddownstream of the reactor, but upstream of the syn-gas and bio-oilcollection tanks to facilitate gas movement from retort to collectiontanks and combustion burners. The pump may take various forms, but willpreferably be capable of conveying a corrosive, and high temperature gasstream. The pump may be a liquid-ring pump, a positive displacementpump, or any other suitable pump or combination of pumps. Preferred arepumps able to tolerate a temperature greater than about 0° C., atemperature greater than about 50° C., a temperature greater than about100° C. Suitable pumps may be able to tolerate a temperature of lessthan about 600° C. The pump preferably delivers a pressure greater thanabout zero (0), but less than about two (2) pounds per square inch whenmeasured at the tank or at the burner.

The syn-gas may be stored in a syn-gas tank. The storage tank may havean inlet for receiving the flow of syn-gas from the reactor and anoutlet in fluid communication with the heating system and a flare pipeor other means for discharging the syn-gas. The communication may becontrolled via a valve, such as a three-way valve, configurable betweena first position where flow is directed to the heating system and asecond position where flow is directed to the flare pipe or otherdischarge means. Alternatively the second position may direct the flowof gas to a storage tank for later use.

The syn-gas management system comprising the syn-gas storage tank,optionally the condenser and bio-oil storage tank may be in the form ofa module. This aids in the transportation of the pyrolysis system todifferent locations and improves the ease of implementation.

The present system may comprise a controller, such as for example aprogrammable logic controller. The controller may be in communicationwith the thermosensor and the valve. The controller switches the valvefrom the first position to the second position upon receiving a signalfrom the thermosensor that, for example, the temperature in the reactoris above optimal levels. The controller may also switch the valve fromthe second to the first position upon receiving a signal from thethermosensor that, for example, the temperature in the reactor is belowoptimal levels. The controller will frequently be a microprocessor. Thecontroller may be a separate module or may be a part of one of the othermodules. As a separate module the controller can be located remote fromthe pyrolysis system. The controller may control more than just thevalve. Depending on the particular embodiment the controller may controla variety of factors such as, for example, the delivery of biomassfeedstock from the dryer to reactor, the residence time of biomass ineach retort, the speed and/or pressure of vacuum pump(s), the residencetime of biochar or bio-coal in any cooling portion of the system, theamount of additive added to biochar or biocoal, the speed of the retort,the speed of the conveyor, or the like, or any combination thereof.

The present system may include a biomass dryer module. The drying canreceive biomass feedstock and may comprise a moisture sensor. The dryerreceives biomass and dries it to reduce the moisture content.Preferably, the moisture content is about 20% or less, about 18% orless, about 15% or less. The dryer may be, for example, a flash dryer, abelt dryer, or a drum dryer. Once the desired moisture content isreached the biomass can be fed into the retort via the inlet means. Arotary valve airlock may be used between the dryer and the reactor inorder to control the delivery of the biomass. In an embodiment of thepresent disclosure hot air from the reactor can be used in the dryerthus reducing the need for external heat sources in the dryer andimproving the overall efficiency of the system.

Any suitable biomass feedstock may be used herein such as, for example,those comprising wood fibre, agricultural fibre, by-products or waste(from plant or animal sources), municipal waste, or the like. Theselection of biomass may vary depending on availability, the desiredoutput and the particular application. Softwood-fibre typicallycomprises three major components: hemicellulose (25-35% dry mass),cellulose (40-50% dry mass), and lignin (25-35% dry mass). The energycontent of wood fibre is typically 17-21 GJ/tonne on a dry basis.

The feedstock may be in particulate form and may have an averageparticle size of from about 1 mm to about 50 mm, such as from about 5 mmto about 25 mm. It is preferred that the feedstock have a moisturecontent of about 15% or less, such as about 10% or less, beforecommencement of pyrolysis.

Depending on the nature of the biomass it may be necessary to preparethe feedstock prior to pyrolysis. For example, the certain feedstocksmay require grinding to produce particles of an appropriate particlesize and/or shape. The present method may comprise a moisture removalstep where the feedstock is heated to such a temperature that moistureis driven off.

The present disclose provides a method of producing bio-char. FIGS. 3 aand 3 b summarizes the steps that may be present in said method. Forinstance, the present method may comprise a hemicellulose decompositionstep. The hemicellulose decomposition step may be at a temperature offrom about 200° C. to about 280° C., such as about 220° C. to about 260°C. The temperature may vary throughout the step or may stay constant.For example, the temperature may be increased at a rate of about 100°C./min or less, about 50° C./min or less, about 35° C./min or less,about 20° C./min or less, about 15° C./min or less, about 10° C./min orless. The step may continue for any suitable length of time such as,about 1 minute or more, about 2 minutes or more, about 3 minutes ormore, about 4 minutes or more, about 5 minutes or more, about 10 minutesor more. It is preferred that by the end of the pyrolysis at least about30%, at least about 40%, at least about 50%, at least about 60%, atleast about 70%, at least about 75%, at least about 80%, at least about85%, of the mass of hemicellulose in the feedstock has been decomposed.

The present method may comprise a cellulose decomposition step. Thecellulose decomposition step may be at a temperature of from about 240°C. to about 400° C., such as about 300° C. to about 380° C. Thetemperature may vary throughout the step or may stay constant. Forexample, the temperature may be increased at a rate of about 100° C./minor less, about 50° C./min or less, about 35° C./min or less, about 20°C./min or less, about 15° C./min or less, about 10° C./min or less. Thestep may continue for any suitable length of time such as, about 1minute or more, about 2 minutes or more, about 3 minutes or more, about4 minutes or more, about 5 minutes or more, about 10 minutes or more. Itis preferred that by the end of the pyrolysis at least about 30%, atleast about 40%, at least about 50%, at least about 60%, at least about70%, of the mass of cellulose in the feedstock has been decomposed.

The present method may comprise a lignin decomposition step. Thecellulose decomposition step may be at a temperature of from about 280°C. to about 500° C., such as about 400° C. to about 500° C. Thetemperature may vary throughout the step or may stay constant. Forexample, the temperature may be increased at a rate of about 100° C./minor less, about 50° C./min or less, about 35° C./min or less, about 20°C./min or less, about 15° C./min or less, about 10° C./min or less. Thestep may continue for any suitable length of time such as, about 1minute or more, about 2 minutes or more, about 3 minutes or more, about4 minutes or more, about 5 minutes or more, about 10 minutes or more. Itis preferred that by the end of the pyrolysis at least about 5%, atleast about 10%, at least about 15%, at least about 20%, of the mass oflignin in the feedstock has been decomposed.

Yields of bio-char, bio-oil, and syn-gas can be altered by varying theprocess temperatures and/or heat transfer rates. While not wishing to bebound by theory, it is believed that higher temperatures tend to favourthe production of bio-oil and/or syn-gas by driving off more of thecondensable volatiles produced from decomposition of cellulose.Conversely, slow pyrolysis may favour the production of bio-char bylimiting the decomposition of cellulose and reducing the amount ofbio-oil produced. Bio-coal production can generally be maximized attemperatures of approximately 285° C. It is believed that at thesetemperatures hemicellulose still decomposes into syn-gas while much ofthe cellulose remains as a solid within the lignin matrix. By limitingthe decomposition of the cellulose fraction, yields of bio-coal can beincreased to around 70%. This type of pyrolysis is known as torrefactionand the resulting bio-char is referred to torrefied bio-char orbio-coal. Producing torrefied bio-char leads to a reduced amount ofbio-oil thus reducing the issues associated with storing and handlingsuch oil. In addition, many industrial scale kilns are already equippedto handle solid fuels such as bio-coal rather than liquid bio-oil.

Certain embodiments according to the present disclosure may providebio-char yields in the range of from about 20% to about 80%, such asabout 25% to about 70%. In general, higher yields are seen withtorrefaction than with other types of pyrolysis. Certain embodimentsaccording to the present disclosure may provide bio-oil yields in therange of from about 10% to about 40%, such as about 20% to about 50%.

According to a further aspect of the invention, a method for convertingbiomass to biochar is provided. The method comprises the steps of:

-   -   (a) introducing biomass to an interior of a retort in a reactor;    -   (b) advancing the biomass through the retort by means of a        retort conveyor such as an auger extending therethrough, the        temperature of the retort being elevated to a point where        pyrolysis of the biomass occurs;    -   (c) collecting biochar from the retort;    -   (d) applying an additive to the biochar;        wherein the additive is selected from soil nutrients and/or        minerals. Examples of minerals include, but are not limited to,        nitrogen, sulphur, magnesium, calcium, phosphorous, potassium,        iron, manganese, copper, zinc, boron, chlorine, molybdenum,        nickel, cobalt, aluminum, silicon, selenium, sodium, compost        tea, humic acids, fulvic acids, plant hormones, pH conditioners,        buffers, or combinations thereof.

Referring to FIG. 1, a general flow diagram of an exemplary biomasspyrolysis system can be seen. Biomass 1 is loaded into a dryer system 2.Biomass may be any suitable such as wood waste, agricultural waste, orany other organic material that can be used to produce bio-char. Arotary valve airlock 3 controls the feeding of the dry biomass feed intoa reactor 4. The reactor produces a biochar stream which is fed to acooling zone 5. Cooling water 6 and additives 7 may be applied to thebiochar. A rotary valve airlock 8 controls the movement of the cooledbiochar to the compaction 9 and bagging 10 areas.

The reactor produces a gaseous stream which passes to a condenser 11which can condense condensable components such as bio-oil. The condensedbio-oil is collected in a bio-oil collection tank 12. A vacuum pump 13moves the remain gaseous stream to a oil tank 14, a syn-gas collectiontank 15. The gaseous stream is fed to a three-way valve 16. A controller18 receives a signal from a thermosensor (not shown) in the reactor 4.Depending on the needs of the reactor the controller 18 can direct thevalve via a control signal 19 to direct the syn-gas to a flare 17 or tothe reactor 4 where the syn-gas can be burnt by a furnace (not shown).

Referring to FIG. 2, an overall side view of a biomass reactor systemaccording to an embodiment of the present disclosure can be seen.Feedstock hopper 1 loads biomass into a cyclone dryer system 2 which hasan exhaust 3. Hot flue gas 5 from the furnace 6 can be used in the dryerassembly. A rotary valve airlock 4 controls the feeding of biomass feedinto one or more anaerobic retorts 7. Biomass may be wood waste,agricultural waste, or any other organic material that can be burned toproduce heat energy. Retorts 7 are tubular and extend through furnace 6.The biomass is advanced through retorts 7 by augers. Heat from furnace 6and the anaerobic conditions in retorts 7 pyrolize the biomass advancingthrough retorts 7, converting the organic feed to form a biochar streamand a gaseous stream.

At least a portion of the gaseous stream is collected by the gascollection system 8 which comprises pipes leading to a gas collectionmanifold. The gases are then fed into a condenser 10 which can condensecondensable components such as bio-oil. The condensed bio-oil iscollected in a bio-oil collection tank 17 which the gaseous stream isfed to a three-way valve 19. Depending on the needs of the furnace 6 thevalve can direct the gas to a flare 18 or to syn-gas burners 9 viasyn-gas pipe 20.

Biochar at the downstream end of retorts 7 is collected and delivered toa cooling retort with a water jacket and auger 13. The assemblycomprises a coolant (water) tank 11 and an additive tank 12. The waterand/or additive are applied to the biochar via spray nozzles 14. Cooledand improved biochar is the delivered to a collection bin 16 controlledvia a rotary valve airlock 15.

It is contemplated that the different parts of the present descriptionmay be combined in any suitable manner. For instance, the presentexamples, methods, aspects, embodiments or the like may be suitablyimplemented or combined with any other embodiment, method, example oraspect of the invention.

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as is commonly understood by one of ordinary skillin the art to which this invention belongs. Unless otherwise specified,all patents, applications, published applications and other publicationsreferred to herein are incorporated by reference in their entirety. If adefinition set forth in this section is contrary to or otherwiseinconsistent with a definition set forth in the patents, applications,published applications and other publications that are hereinincorporated by reference, the definition set forth in this sectionprevails over the definition that is incorporated herein by reference.Citation of references herein is not to be construed nor considered asan admission that such references are prior art to the presentinvention.

Use of examples in the specification, including examples of terms, isfor illustrative purposes only and is not intended to limit the scopeand meaning of the embodiments of the invention herein. Numeric rangesare inclusive of the numbers defining the range. In the specification,the word “comprising” is used as an open-ended term, substantiallyequivalent to the phrase “including, but not limited to,” and the word“comprises” has a corresponding meaning.

The invention includes all embodiments, modifications and variationssubstantially as hereinbefore described and with reference to theexamples and figures. It will be apparent to persons skilled in the artthat a number of variations and modifications can be made withoutdeparting from the scope of the invention as defined in the claims.Examples of such modifications include the substitution of knownequivalents for any aspect of the invention in order to achieve the sameresult in substantially the same way.

1. A system for pyrolysis of biomass, the system comprising: a reactorcomprising at least one retort extending therethrough, said retortscomprising a conveyor, an inlet, and an outlet; the reactor furthercomprising at least one thermosensor, the thermosensor capable ofgenerating a signal when the temperature is above a predetermined value;a heating system adapted to heat the reactor; a syn-gas managementsystem; the management system comprising a syn-gas storage tank havingan inlet and an outlet, said inlet in fluid communication with thereactor, and said outlet in fluid communication with the heating systemand a syn-gas outlet wherein the communication is controlled via a valveconfigurable between a first position where flow is directed to theheating system and a second position where flow is directed to the flarepipe; and a controller in communication with the thermosensor and thevalve; wherein the controller switches the valve from the first positionto the second position upon receiving a signal from the thermosensorthat the temperature in the reactor is above a predetermined value.
 2. Asystem for pyrolysis of biomass, the system comprising: a reactor havinga retort extending therethrough, said retort comprising a conveyor, aninlet, and an outlet; the reactor further comprising at least onethermosensor, the thermosensor capable of generating a signal when thetemperature is below a predetermined value; a heating system adapted toheat the reactor; a syn-gas management system; the management systemcomprising a syn-gas storage tank having an inlet and an outlet, saidinlet in fluid communication with the reactor, and said outlet in fluidcommunication with the heating system and a syn-gas outlet wherein thecommunication is controlled via a valve configurable between at least afirst position where flow is directed to the heating system and a secondposition where flow is directed to the flare pipe; and a controller incommunication with the thermosensor and the valve; wherein thecontroller switches the valve from the second position to the firstposition upon receiving a signal from the thermosensor that thetemperature in the reactor is below a predetermined value.
 3. The systemof claim 1 or 2 comprising a dryer for drying the biomass prior to entryinto the reactor.
 4. The system of claim 1 or 2 comprising a biochardelivery system for receiving the biochar from the reactor.
 5. Thesystem of claim 4 wherein the biochar delivery system comprises acooling zone, a compaction area, with a rotary airlock valvetherebetween.
 6. The system of claim 1 or 2 comprising an additivedelivery system for introducing additives to the biochar.
 7. The systemof claim 4-6 wherein the additive delivery system is located with thebiochar delivery system.
 8. The system of claim 1 or 2 wherein thecontroller is a programmable logic controller.
 9. The system of claim 1or 2 wherein the controller further controls the speed of the conveyor.10. The system of any of claims 1-9 wherein the conveyor is an auger.11. A method for converting biomass to biochar, the method comprises thesteps of: introducing biomass to an interior of a retort in a reactor,the heated reactor; advancing the biomass through the retort by means ofa retort conveyor extending therethrough, the temperature of the retortbeing elevated to a point where pyrolysis of the biomass occurs;collecting biochar from the retort; and applying a additive to thebiochar.
 12. The method of claim 11 wherein the additive is selectedfrom soil nutrients and/or minerals.
 13. The method of claim 11 whereinthe additive is selected from nitrogen, sulphur, magnesium, calcium,phosphorous, potassium, iron, manganese, copper, zinc, boron, chlorine,molybdenum, nickel, cobalt, aluminum, silicon, selenium, sodium, composttea, humic acids, fulvic acids, plant hormones, pH conditioners,buffers, or combinations thereof.
 14. A modular pyrolysis apparatus,comprising: a reactor module comprising at least one retort comprising aconveyor, an inlet, and an outlet; at least one thermosensor; and aheating system adapted to heat the reactor; a syn-gas management modulecomprising a syn-gas storage tank, and a valve configurable between atleast a first and a second position; a control module comprising acontroller adapted to communicate with the thermosensor and the valve.15. The apparatus of claim 14 wherein a syn-gas management moduleadditionally comprises a condenser and a bio-oil storage tank.
 16. Theapparatus of claim 14 wherein the controller is a programmable logiccontroller.
 17. The apparatus of claim 14 wherein the controller furthercontrols the speed of the conveyor.